Method and device for producing shaped bodies

Abstract

A method and apparatus for manufacturing shaped bodies made of fibers, particles containing cellulose and/or particles containing lignocellulose which are admixed with a binder and scattered to form a mat. The mat is preheated by supplying thermal energy from an interior of the mat outwardly to a surface of the mat and then pressing the mat into the shaped body.

What is claimed is:  
     
       1. A method of manufacturing of shaped bodies, in particular fiberboard and chipboard, in which fibers, particles containing cellulose or particles containing lignocellulose with an admixed binder are scattered to form a mat ( 1 ) and preheated before the mat ( 1 ) is pressed to the shaped body while supplying heat and pressure, characterized in that the preheating of the mat ( 1 ) consisting of the pre-compacted or pre-pressed fibers or like particles takes place by the supply of thermal energy from the interior of the mat ( 1 ) outwardly to the surface of the mat ( 1 ). 
     
     
       2. A method in accordance with  claim 1 , characterized in that at least one additive, in particular a catalyst for the binder contained in the mat ( 1 ), is also introduced into the mat ( 1 ) from the interior of the mat ( 1 ) outwardly to the surface of the mat ( 1 ) and/or in that the pre-heating is effected by the supply of a heated thermal medium, in particular of a fluid thermal medium, advantageously in the form of hot air or saturated or superheated steam. 
     
     
       3. A method in accordance with  claim 1  characterized in that two separate mats ( 1 ′,  1 ″) are first scattered, pre-compacted or pre-pressed to form the mat ( 1 ) and in that these two separate mats ( 1 ′,  1 ″) are each brought together such that the sides of the mats ( 1 ′,  1 ″) facing one another form the interior of the mat ( 1 ) and the sides of the mats ( 1 ′,  1 ″) remote from one another form the upper side and the lower side of the mat ( 1 ) respectively. 
     
     
       4. A method in accordance with  claim 3 , characterized in that the supply of the thermal energy and, optionally, the introduction of the additives, is effected directly prior to the bringing together of the mats ( 1 ′,  1 ″). 
     
     
       5. A method in accordance with  claim 1  characterized in that the mat ( 1 ) has a mat-like build-up, in that it is cut open substantially parallel to its upper side and its lower side and in that, where applicable, the introduction of the additive is effected through the cut surfaces both in the direction of the upper side and the lower side of the mat ( 1 ). 
     
     
       6. A method in accordance with  claim 2  characterized in that the introduction of the additives into the mat ( 1 ) is effected by injection through a nozzle. 
     
     
       7. A method in accordance with  claim 2  characterized in that the additive is introduced into the mat ( 1 ) in dissolved form as a fluid, in particular in liquid form. 
     
     
       8. A method in accordance with  claim 2  characterized in that the additive is introduced into the mat ( 1 ) prior to and/or simultaneously with and/or subsequent to the pre-heating of said mat ( 1 ). 
     
     
       9. A method in accordance with  claim 2  characterized in that hardeners are used as the additives, in particular ammonium chloride, ammonium sulfate, ammonium nitrate and/or hexamethylene tetramine, and/or formic acid, maleic acid, citric acid, sulfuric acid, hydrochloric acid, aluminum sulfate (chloride), persulfate, phosphoric acid; and/or water repellent agents such as paraffin; and/or wood preservatives, fungicides; and/or fire protection agents; and/or formaldehyde scavengers such as urea; and/or dilutants; and/or dyes. 
     
     
       10. A method in accordance with  claim 1  characterized in that the mat ( 1 ) is pre-pressed prior to the pre-heating and/or the introduction of the additive. 
     
     
       11. An apparatus for the manufacture of shaped bodies, in particular of fiberboard and chipboard, by scattering fibers, particles containing cellulose or particles containing lignocellulose and a binder to form a mat and preheating the mat, the apparatus comprising a scattering station, a forming line ( 2 ), a pressing station ( 5 ) and a heating device ( 13 ) inserted before the pressing station ( 5 ) for the heating of a mat ( 1 ) scattered by the scattering station onto the forming line ( 2 ) prior to entry into the pressing station ( 5 ), characterized in that the heating device ( 13 ) supplies heat from the interior of the mat ( 1 ) outwardly toward the surface of the mat ( 1 ). 
     
     
       12. An apparatus in accordance with  claim 11  characterized in that the heating device ( 13 ) is designed for the introduction of additives, in particular of a catalyst for the binder contained in the mat ( 1 ), into the mat ( 1 ) also from the interior of the mat ( 1 ) outwardly toward the surface of the mat ( 1 ). 
     
     
       13. An apparatus in accordance with  claim 11  characterized in that a separating device, in particular formed as a cutting device ( 6 ), is provided with which the mat ( 1 ) can be divided into at least two part mats, in particular into a lower and an upper part mat ( 11 ,  12 ), and in that the heating device ( 13 ) is arranged in the region between the part mats ( 11 ,  12 ). 
     
     
       14. An apparatus in accordance with  claim 13  characterized in that the separating device is formed as a saw ( 6 ), in particular as a band saw, and preferably as an endless band saw. 
     
     
       15. An apparatus in accordance with  claim 13  characterized in that the cutting direction of the cutting device ( 6 ) is directed opposite to the transport direction of the mat ( 1 ) substantially parallel to the surface of the forming line ( 2 ). 
     
     
       16. An apparatus in accordance with  claim 13  characterized in that the separating device ( 6 ) is arranged upstream of the heating device ( 13 ) in the transport direction of the mat ( 1 ). 
     
     
       17. An apparatus in accordance with  claim 11  characterized in that the heating device ( 13 ) includes a heating chamber ( 15 ) which extends substantially over the full width of the mat ( 1 ) and which has respective outlet openings in its regions adjacent to the part mats ( 11 ,  12 ), in particular slit-like outlet openings ( 28 ), for the dispensing of heating medium, in particular of steam, from the heating chamber ( 15 ) into the mat ( 1 ) and optionally includes additive outlet openings ( 48 ,  41 ) for the introduction of the additives into the mat ( 1 ). 
     
     
       18. An apparatus in accordance with  claim 17  characterized in that the outlet openings ( 28 ) are made at least partly closable, in particular via a blocking slide ( 31 ). 
     
     
       19. An apparatus in accordance with  claim 17  characterized in that the size of the outlet openings ( 28 ) is adjustable. 
     
     
       20. An apparatus in accordance with  claim 17  characterized in that the heating chamber ( 15 ) includes at least one lateral supply means ( 24 ), in particular disposed outside of the mat ( 1 ), for the supply of the heating medium. 
     
     
       21. An apparatus in accordance with  claim 17  characterized in that supply means ( 24 ) for the supply of heating medium are provided at the two end faces of the heating chamber ( 15 ). 
     
     
       22. An apparatus in accordance with  claim 17  characterized in that a broadening device ( 16 ) is provided upstream of the heating chamber ( 15 ) in the transport direction, in particular a broadening device ( 16 ) having ramps ( 18 ) for the expansion of the spacing between the part mats ( 11 ,  12 ), and in that, where applicable, the additional outlet openings ( 48 ) are made in the broadening device, in particular in the run-up ramp ( 18 ). 
     
     
       23. An apparatus in accordance with  claim 17  characterized in that a uniting apparatus ( 17 ) is arranged in the transport direction downstream of the heating chamber ( 15 ), in particular a uniting device ( 17 ) with a down ramp ( 19 ) for the simultaneous uniting of the part mats ( 11 ,  12 ) to a complete mat, and in that, where applicable, the additional outlet openings ( 51 ) are made in the uniting device, in particular in the down ramp ( 19 ). 
     
     
       24. An apparatus in accordance with  claim 17  characterized in that the outlet openings ( 28 ) simultaneously form the additional outlet openings ( 48 ,  51 ). 
     
     
       25. An apparatus in accordance with  claim 22  characterized in that the broadening device ( 16 ) and/or the uniting device ( 17 ) comprise(s) a plurality of sections, in particular completely separated from one another, and preferably formed as hollow spaces ( 49 ′,  49 ″,  50 ′,  50 ″). 
     
     
       26. An apparatus in accordance with  claim 11  characterized in that at least one boundary unit impermeable to the heating medium, in particular in the form of a guide and sealing panel ( 29 ), is provided to the side of the mat ( 1 ) in the region ofthe heating device ( 13 ). 
     
     
       27. An apparatus in accordance with  claim 26  characterized in that the boundary unit is displaceably formed, and in particular is displaceable together with the blocking slide ( 31 ). 
     
     
       28. A heating device for pre-heating a mat made of at least one of fibers, particles containing cellulose and particles containing lignocellulose and a binder and a heating device for the heating of a mat supplying heat from an interior of the mat outwardly toward a surface of the mat. 
     
     
       29. A method for manufacturing a shaped body made with at least one of fibers, particles containing cellulose and particles containing lignocellulose and an admixed binder forming a mixture, the mixture comprising scattering the mixture to form a mat, preheating the mat by supplying thermal energy from an interior of the mat outwardly to a surface of the mat, and thereafter pressing the mat into the shaped body. 
     
     
       30. Apparatus for manufacturing a shaped body having at least one of fibers, particles containing cellulose and particles containing lignocellulose and admixed with a binder into a mixture, the apparatus comprising a scattering station for forming a mat with the mixture, a heating device for supplying heat from an interior of the mat outwardly toward a surface of the mat, and a pressing station downstream of the heating device for pressing the heated mat into the shaped body.